PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER PUMP CIRCUIT AND RADIATOR ON CERTAIN G3516 GENERATOR SETS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER PUMP CIRCUIT AND RADIATOR ON CERTAIN G3516 GENERATOR SETS
Usage:
TEBE8504-01
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02Jan2019
(Revised 06Mar2019)
V219
V21A
V21C
V21D
V461
V462
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Before/After
(Limited distribution)
PRODUCT SUPPORT PROGRAM FOR REWORKING THE JACKET WATER PUMP CIRCUIT AND RADIATOR ON CERTAIN G3516 GENERATOR SETS
1361
PS46102
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NOTE:
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:
This Program must be administered either before or after failure.
In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46102" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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NOTE:
The information supplied in this service letter may not be valid after the termination date of this program.
Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
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NOTE:
This Revised Service Letter replaces the 02Jan2019 Service Letter. Changes have been made to the Affected Product, and Service Claim Allowances.
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TERMINATION DATE
31Jan2021
PROBLEM
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Jacket Water pump cavitation, radiator foaming, and engine overheating may occur on certain G3516 Generator Sets equipped with 394-9990 radiator group, or 460-3256 radiator group.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
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Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.
The user should ensure that the product will not be damaged and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, energizing, or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch and local and remote controls before you perform any service to the machine.
Rework Action Required
Instructions for part procurement, assembly, and installation should have already been provided to the dealer. If a dealer does not have these instructions, have the Dealer Technical Communicator (TC) submit a request to CPI number 429834 through CPI Feedback within the Service Information Management System (SIMSi).
The cooling system must be drained to complete the rework. Retain the coolant for reuse.
Group 1 and Group 2: Remove and inspect 416-0610 PUMP GP-WATER. Refer to Image1. If pump impeller damage due to cavitation if found, replace with same part number. Refer to Media Number SEBF8418 for water pump reuse and salvage guidelines. If no damage if found, but leakage is seen, replace 416-0603 SEAL GP and reinstall pump. Refer to the following sections within Disassembly and Assembly G3500 Engines Media Number -SENR6419: Water Pump - Remove, Water Pump ? Disassemble, Water Pump ? Assemble, Water Pump ? Install.
Group 1: Install locally procured RADIATOR_CORE.
Group 2: Install 7W-3446 ORIFICE after the jacket water (Hot Side) thermostat outlet. Refer to Image2. Install locally procured TANK_EXPANSION. Refer to Image3.
Refer to the attached Rework Procedure.
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Image1
Image2
Image3
SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-5000 hrs, 0-90 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-10000 hrs, 91-92 mo
92.0%
92.0%
0.0%
0.0%
8.0%
8.0%
10001-15000 hrs, 93-94 mo
83.0%
83.0%
0.0%
0.0%
17.0%
17.0%
15001-20000 hrs, 95-96 mo
75.0%
75.0%
0.0%
0.0%
25.0%
25.0%
20001-25000 hrs, 97-98 mo
67.0%
67.0%
0.0%
0.0%
33.0%
33.0%
25001-30000 hrs, 99-100 mo
58.0%
58.0%
0.0%
0.0%
42.0%
42.0%
30001-35000 hrs, 101-102 mo
50.0%
50.0%
0.0%
0.0%
50.0%
50.0%
35001-40000 hrs, 103-104 mo
42.0%
42.0%
0.0%
0.0%
58.0%
58.0%
40001-45000 hrs, 105-106 mo
33.0%
33.0%
0.0%
0.0%
67.0%
67.0%
45001-50000 hrs, 107-108 mo
25.0%
25.0%
0.0%
0.0%
75.0%
75.0%
50001-55000 hrs, 109-110 mo
17.0%
17.0%
0.0%
0.0%
83.0%
83.0%
55001-60000 hrs, 111-112 mo
8.0%
8.0%
0.0%
0.0%
92.0%
92.0%
NOTE: This is a 32.0-hour job for Group 1
Refer to Image 1.1 for maximum allowance per generator set for procurement of the RADIATOR_CORE (USD).
Image1.1
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-60000 hrs, 0-112 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 10.0-hour job for Group 2
The maximum allowance per generator set for the procurement of the TANK_EXPANSION and HOSE_HYDRAULIC is $2000.00 USD.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group Number 1
Install locally procured RADIATOR_CORE conforming to the following specifications. Refer to Image1.1.1, Image1.1.2, and Image1.1.3.
Image1.1.1
Image1.1.2
Image1.1.3
Group Number 2
Remove 7E-6016 GASKET AS. and install 7W-3446 ORIFICE in its place. Install 7W-3446 ORIFICE after the jacket water (Hot Side) thermostat outlet. Refer to Image2.1.1. Install locally procured TANK_EXPANSION. Refer to Image2.1.2 and Image2.1.3. TANK_EXPANSION must conform to the following specifications.
Tank Size: 620 mm (24.4 inches) x 970 mm (38 inches) x 444 mm (17.5 inches)
Install HOSE_HYDRAULIC from bottom of expansion tank to as close as possible to the inlet of the jacket water pump. Refer to Image2.1.4. HOSE_ HYDRAULIC must conform to the following specifications.
